FRONT BRAKE INSTALLATION

Tech Tips


  • Use the same procedure for the RH and LH sides.

  • The following procedure is for the LH side.


  1. INSTALL FRONT DISC


    1. A003D24E01
      Text in Illustration
      *1 Matchmark

      Align the matchmarks of the disc and axle hub, and install the front disc.

      Note

      When replacing the front disc with a new one, select an installation position where the front disc has minimal runout.

  2. INSTALL FRONT DISC BRAKE CYLINDER MOUNTING


    1. A003CY3

      Install the disc brake cylinder mounting to the steering knuckle with the 2 bolts.

      Torque:
      107 N*m  { 1089 kgf*cm, 79 ft.*lbf }

  3. INSTALL FRONT DISC BRAKE BUSH DUST BOOT


    1. A003B67E01
      Text in Illustration
      *1 Lithium soap base glycol grease

      Apply a light coat of lithium soap base glycol grease to the entire circumference of 2 new front disc brake bush dust boots where they contact the front disc brake cylinder mounting, and the entire inner circumference of both ends of the boots.

      Note

      Apply a sufficient amount of lithium soap base glycol grease to the entire circumference of the front disc brake bush dust boot and front disc brake cylinder mounting contact surfaces.

      Tech Tips

      Apply at least 0.3 g (0.01 oz.) of lithium soap base glycol grease to the front disc brake bush dust boot.

    2. Install the 2 front disc brake bush dust boots to the disc brake cylinder mounting.

  4. INSTALL FRONT DISC BRAKE CYLINDER SLIDE BUSH


    1. A003CKSE01
      Text in Illustration
      *1 Lithium soap base glycol grease

      Apply lithium soap base glycol grease to the front disc brake cylinder slide bush pin, as shown in the illustration.

    2. Install a new front disc brake cylinder slide bush to the front disc brake cylinder slide pin.

  5. INSTALL FRONT DISC BRAKE CYLINDER SLIDE PIN


    1. A003EO4E01
      Text in Illustration
      *1 Lithium soap base glycol grease

      Apply lithium soap base glycol grease to the sliding part and the seal surface of the 2 front disc brake cylinder slide pins.

    2. A003DLB

      Install the 2 front disc brake cylinder slide pins to the disc brake cylinder mounting.

  6. INSTALL FRONT DISC BRAKE PAD SUPPORT PLATE

    A003EIS

    1. Install 2 new front disc brake pad support plates LH and 2 new front disc brake pad support plates RH to the front disc brake cylinder mounting.

      Note

      Be sure to install each front disc brake pad support plate in the correct position and direction.

  7. INSTALL FRONT DISC BRAKE PAD


    1. A003BE8

      Install the 2 disc brake pads to the disc brake cylinder mounting.

      Note

      Make sure there is no oil or grease on the friction surfaces of the disc brake pads or the front disc.

  8. INSTALL DISC BRAKE CYLINDER ASSEMBLY


    1. A003BOY

      Hold the front disc brake cylinder slide pin and install the disc brake cylinder assembly to the disc brake.

    2. A003ENC

      Install a new lower bolt to the front disc brake cylinder.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
    3. A003CVR

      Support brake cylinder slide pin as shown in the illustration.

    4. Install a new upper bolt to the front disc brake cylinder.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  9. CONNECT FRONT FLEXIBLE HOSE


    1. A003AR4

      Install a new gasket and connect the front flexible hose to the disc brake cylinder assembly with a new union bolt.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

      Tech Tips

      Install the flexible hose lock securely into the lock hole in the disc brake cylinder.

  10. FILL RESERVOIR WITH BRAKE FLUID


    1. Fill the reservoir with brake fluid.

      Brake Fluid
      SAE J1704 or FMVSS No. 116 DOT 4

      Note

      Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.

  11. BLEED BRAKE LINE

    Note


    • Bleed the brake line of the wheel farthest from the master cylinder first.

    • Add brake fluid to keep the level between the MIN and MAX lines of the reservoir while bleeding the brakes.


    1. Connect a vinyl tube to the bleeder plug.

    2. Depress the brake pedal several times, and then loosen the bleeder plug with the pedal depressed.*1

    3. When fluid stops coming out, tighten the bleeder plug, and then release the brake pedal.*2

    4. Repeat *1 and *2 until all the air in the fluid is completely bled out.

    5. Tighten the bleeder plug completely.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    6. Repeat the above procedure for each wheel to bleed the brake line.

  12. BLEED CLUTCH LINE (for 1AD-FTV)

    A003B3WE01
    Text in Illustration
    *1 Bleeder Plug Cap
    *2 Bleeder Plug

    1. Remove the bleeder plug cap.

    2. Connect a vinyl tube to the bleeder plug.

    3. Depress the clutch pedal several times, and then loosen the bleeder plug while the pedal is depressed.

    4. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

    5. Repeat the previous 2 steps until all the air in the fluid is completely bled.

    6. Tighten the bleeder plug.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    7. Install the bleeder plug cap.

    8. Check that all the air has been bled from the clutch line.

  13. BLEED CLUTCH LINE (for 2AD-FHV)

    A003B3WE01
    Text in Illustration
    *1 Bleeder Plug Cap
    *2 Bleeder Plug

    1. Remove the bleeder plug cap.

    2. Connect a vinyl tube to the bleeder plug.

    3. Depress the clutch pedal several times, and then loosen the bleeder plug while the pedal is depressed.

    4. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

    5. Repeat the previous 2 steps until all the air in the fluid is completely bled.

    6. Tighten the bleeder plug.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    7. Install the bleeder plug cap.

    8. Check that all the air has been bled from the clutch line.

  14. BLEED CLUTCH LINE (for 2AD-FTV)

    A003B3WE01
    Text in Illustration
    *1 Bleeder Plug Cap
    *2 Bleeder Plug

    1. Remove the bleeder plug cap.

    2. Connect a vinyl tube to the bleeder plug.

    3. Depress the clutch pedal several times, and then loosen the bleeder plug while the pedal is depressed.

    4. When fluid no longer comes out, tighten the bleeder plug, and then release the clutch pedal.

    5. Repeat the previous 2 steps until all the air in the fluid is completely bled.

    6. Tighten the bleeder plug.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    7. Install the bleeder plug cap.

    8. Check that all the air has been bled from the clutch line.

  15. INSPECT FOR BRAKE FLUID LEAK

  16. INSPECT BRAKE FLUID LEVEL


    1. A010LQYE01

      Check the fluid level.

      If the brake fluid level is lower than the MIN line, check for leaks and inspect the disc brake pads. If necessary, refill the reservoir with brake fluid to the MAX line after repair or replacement.

      Brake Fluid
      SAE J1704 or FMVSS No. 116 DOT 4

  17. INSTALL FRONT WHEEL

    Torque:
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }